Diaper construction



llg- 5, 1959 s. M. SCHWARTZ 3,459,186

DIAPER CONSTRUCTION Filed April 1l, 1967 2 Sheets-Sheet 1 2 www l Wl# l. HHM, I

Milf" il 'm1- lil mnu x I NVEN''OR. SAMUEL M. SCHWARTZ his ATTORNEYS Aug' 5 1969 s. M. SCHWARTZ 3,459,186

DIAPER CONSTRUCTION Filed April 11, 1967 2 Sheets-Sheet 2 FIG. 5

F/G. a l

. INVENTOR. SAMUEL. M. SCHWARTZ m' 4.,.. u M

ms Arma/vers United States Patent C) Int. Cl. A61f 13/16 U.S. Cl. 12S-284 16 Claims ABSTRACT OF THE DISCLOSURE An improved diaper having two or more layers of material. The layer next to the wearers skin is of a soft nonabsorbent material, such as polypropylene, which may be knitted, woven or tufted, and has an uneven surface with interstices and raised portions, such as ribs or tufts, thereon to form a moisture barrier and permit air to circulate around the raised portions and the wearers skin, thereby maintaining the skin in a dry state. The underlayer consists of an absorbent material which absorbs body uids as they pass from the upper layer through the interstices into the underlayer. The diaper may also have an intermediate layer of nonabsorbent material having smaller interstices and being disposed between the nonabsorbent upper layer and the absorbent underlayer.

This is a continuation-in-part of application Ser. No. 542,519, `filed Apr. 14, 1966. This invention relates to improved diapers, and more specifically to diapers having at least one underlayer of absorbent material attached to an upper layer of soft nonabsorbent material having an uneven upper surface with interstices through which body fluids pass into the absorbent layer and having raised portions which facilitate ventilation of the wearers skin to maintain the skin in a dry condition. It also relates to a diaper as described above having an intermediate nonabsorbent layer with interstices which is disposed between the upper and under layer of the diaper.

It has long been an objective ofthe diaper construction art to construct a diaper of such a nature that the skin of the wearer remains dry after the elimination of uids from the body. The retention of'body liuids next to the skin of the wearer, as in conventional diapers of single or multiple layer absorbent material, causes extreme discomfort to the wearer, as well as a disagreeable odor. More importantly, retained fluids cause irritations and inammations of the skin, such as diaper rash, perspiration gland obstruction, chapping and skin masceration. The primary causes of these skin irritations are the removal of natural skin oils byconstant exposure to moisture and the action of bacteria on the skin which decompose the uric acids contained in the body fluids into irritating aqueous ammonia and other harsh compounds harmful to the skin;

Several attempts have been made to construct diapers with features which would maintain the skin of the'wearer in a dry state and thus prevent diaper rash and other skin irritations. Diapers have been constructed using two layers of fabric, one layer of hydrophobic or nonabsorbent material and a second layer of hydrophilic or absorbent material, with the hydrophobic material next to the wearers skin. Variations of this have included loosely knitted hydrophobic materials and solid sheets of a plastic material with holes in them. These attempts at maintaining dry skin and reducing skin irritations have not succeeded for several reasons. The interstices in the knitted or woven hydrophobic material retained considerable amounts of body fluids by means of capillary action and also allowed moisture to pass back from the absorbent material 3,459,186 Patented Aug. 5, 1969 ice to the skin. In addition, the skin of the wearer did not dry because the skin was separated from the moist absorbent layer by only the relatively thin, fiat layer of hydrophobic material with interstices which allowed the moisture in the absorbent material to remain in contact with the wearers skin. And, more importantly, the hydrophobic layer did not permit the flow of air to reach the wearers skin to aid in the evaporation process, and the skin remained moist. All of these disadvantages are readily apparent in the diapers available heretofore.

It is therefore an objective of this invention to provide a diaper construction which facilitates the rapid drying of the wearers skin and the prevention of diaper rash and skin irritations caused by exposure of the skin to excessive moisture. It is a further object of the invention to provide a diaper with one or two layers of nonabsorbent or hydrophobic material over one or more layers of absorbent or hydrophilic material with the hydrophobic layer having an uneven upper surface with interstices and raised portions above the plane of the surface (l) to allow the rapid passage of body fluids into the absorbent layer, (2) to facilitate the -flow of air around the wearers skin, (3) to prevent the return passage of body lfluids from the absorbent layer to the skin, and (4) to prevent the capillary retention of moisture in the interstices of the nonabsorbent layer.

The objectives of this invention are achieved by the diaper construction of the following description. The diaper has an upper layer of soft nonabsorbent or hydrophobic material which may be knitted, woven, tufted or of other appropriate construction. The upper layer has an uneven upper surface with raised portions, such as knitted ribs, ridges or tufts, thereon above the surface with interstices between and through the raised portions. The raised portions permit the flow of air around the skin of the wearer by maintaining air channels throughout the nonabsorbent layer. The raised portions also perform the important function of holding the surface of the skin away from direct contact with an absorbent underlayer. The interstices in the upper layer permit the rapid passage `of the body fluids into an underlayer of absorbent material, and they are of such size as to hinder or prevent the capillary retention of moisture within them. The attached absorbent underlayer of the diaper absorbs the body fluids and retains them distant from the wearers skin. The ventilation of the wearers skin and the physical separation of the skin from the absorbent layer maintain the skin in a dry condition and prevent or greatly minimize the incidence of skin irritation and inflammation. The comfort of the wearer is enhanced and the good health and well-being of the wearer are further protected.

It is also within the contemplation of this invention to have a second intermediate layer of nonabsorbent material disposed between the nonabsorbent upper layer and the absorbent underlayer. The intermediate nonabsorbent layer has smaller interstices than the upper layer, which effectively prevent the return passage of moisture from the absorbent layer through the nonabsorbent layers to contact with the wearers skin. It is also possible to combine the upper and intermediate nonabsorbent layers into one nonabsorbent layer having interstices and an uneven upper surface with raised portions thereon above the plane of the surface, and having a lower surface with smaller interstices therein.

Referring now to the drawings:

FIGURE 1 is a plan view of the composite layers of soft materials forming the improved diaper;

FIGURE 2 is a cross-sectional view of FIGURE l taken along line 2-2;

FIGURE 3 is an enlarged detailed view of a section of FIGURE 1 showing the ribbed knitted upper layer o nonabsorbent material;

FIGURE 4 is a plan view of another embodiment showing a body-contour shaped diaper having depressed edges on both of two opposite sides;

FIGURE 5 shows a plan View of still another embodiment with smaller tab margins for attaching the diaper around the wearer;

FIGURE 6 illustrates a waflle pattern of ridges or ribs on the upper surface of the upper nonabsorbent layer;

FIGURE 7 illustrates a serpentine pattern of knitted or woven ribs on the upper surface of the upper nonabsorbent layer; and

FIGURE 8 is an enlarged detailed view of a cross-section of another embodiment.

One embodiment of the invention, as shown in FIG- URES 1, 2 and 3, includes a nonabsorbent upper layer 10 constructed of a knitted, ribbed nonabsorbent material, preferably polypropylene, although any other nonabsorbent or hydrophobic material may be used, such as polyvinyl chloride and the like. The upper layer 10 may also be woven, tufted or of any other construction which provides interstices and raised portions. The upper layer 10 has interstices 12 through which the body fluids flow to become absorbed in an absorbent underlayer 13. The interstices 12 are preferably 5 mm. to 15 mm. in diameter; however, larger interstices may be used since it is important that no moisture is retained by capillary action.

Extending above the plane 15 of the surface of the nonabsorbent upper layer 10 are the raised portions 16, which are knitted ribs in this embodiment. The raised portions 16 may be knitted or woven sinuous ribs or ridges in the form of a waffle pattern 16a, as shown in FIGURE 6, or in any other suitable pattern, such as the serpentine pattern 16b of FIGURE 7. The raised portions 16 may also be tufts projecting out of the woven upper layer 10 or a plurality of closely adjacent ridges with valleys disposed between the groups. The important considerations are that the raised portions 16 extend above the remainder of the surface 15 of the upper layer 10 to support the skin of the wearer a substantial distance from the absorbent yunderlayer 13, and that they permit the circulation of air around the skin of the wearer. The raised portions 16 may also have interstices 12 located in them, as will most commonly be the situation when the upper layer 10 is of a knitted ribbed construction. The raised portions 16 should extend to a height 11 of approximately 1 mm. to approximately 5 mm. above the plane 15 of the upper layer surface and have a cross-sectional dimension 25 of approximately l mm. to approximately 5 mm. The distance 17 between the raised portions 16 may vary according to the type of construction used; however, the preferred distance 17 is approximately 3 mm. to approximately 15 mm.

The underlayer 13 of the diaper is composed of one or more sheets of an absorbent material, such as cotton, terrycloth, gauze, flannelette or the like. The absorbent underlayer 13 may have a backing material 18 of net, gauze or nonabsorbent material to enclose the bottom or outside of the diaper.

As means for fastening the diaper around the wearer the diaper may have a margin 19 of material extending from both of two opposite sides of the diaper. The material of margin 19 may be absorbent or nonabsorbent, and may be of the same material as the backing material 18. For example, the backing material may be cut wider than the width of the congruent nonabsorbent 10 and absorbent 13 layers and doubled back to the edge 21 of the congruent layers 10 and 13 to form the margin 19. The margins 19 can be in the form of tabs 22, as shown in FIG- URES 4 and 5. The tabs 22 do not require as much material and are preferably placed at or near one end of the diaper for ease of attaching the diaper around the wearer. An additional advantage in the use of tabs 22 is that the skin of the wearer is in Contact with only the nonabsorbent material of the upper layer 10. No other material touches the wearers skin. As another means of attachment around the wearer, the diaper may have snaps, clasps, or the like attached to the diaper at any location which is convenient for a comfortable attachment of the diaper around the wearer.

The several contiguous layers 10, 13, 18 are bound together by appropriate means, such as sewing, preferably at the edges 21, 23, 24.

The diaper may have any shape or size convenient for attaching around the wearer and comfortable for the wearer. It has been found that the body contour shape, with depressed sides 41 as illustrated in FIGURE 4 is especially satisfactory for small infants because of the ease and rapidity of attachment. The generally rectangular shaped diapers as illustrated in FIGURES 1 and 5, are adaptable to any wearer and are not limited in the dimension of length and width.

Another embodiment of the diaper construction, illustrated by FIGURE 8, includes an intermediate layer 34 of nonabsorbent material disposed between the nonabsorbent upper layer 30 and the absorbent lower layer 33. The nonabsorbent intermediate layer 34 may be knitted or woven, and it contains interstices which are preferably smaller than those found in the upper layer 30, in the range of 0.5 mm. to 10 mm. The intermediate layer 34 optimally has interstices of approximately 3 mm. to 5 mm. dimensions. The presence of the intermediate nonabsorbent layer 34 ensures that the wearers skin is further physically isolated from the absorbent underlayer 33, and also prevents moisture from returning to the wearers skin from the underlayer 33. The intermediate nonabsorbent layer 34 also permits the interstices 32 in the upper layer 30 to be larger than otherwise, since the intermediate layer 34 functions as the effective moisture barrier. The larger interstices 32 in the upper layer 30 permit better ventilation of the wearers skin, thereby achieving and maintained a dry condition more quickly and easily.

The nonabsorbent upper layer 30 `and the nonabsorbent intermediate layer 34 may be constructed in a composite manner, resulting in a single layer of knitted woven or otherwise fabricated material. The composite nonabsorbent layer preferably has raised portions, as ribs, ridges or tufts, extending above the plane of the upper surface and has interstices in the raised portions to allow the body iluids to pass rapidly into the absorbent underlayer 33. The underside of the composite nonabsorbent layer has smaller interstices than the raised portions, and preferably is of a tighter knit or weave than the raised portions. The tighter underside of the nonabsorbent composite layer forms a physical moisture barrier between the wearers skin `and the absorbent underlayer 33 and thereby prevents the body fluids from returning to the wearers skin after they have passed into the absorbent underlayer 33.

It is seen that diapers of the construction described herein prevent or minimize skin irritations and inflammations which are caused by prolonged contact with the irritants yfound in body fluids. The nonabsorbent and ribbed or raised portions of the diaper interpose a barrier between the skin and the moist absorbent underlayer of the diaper. T he interstices permit the rapid dispersion of body fluids into the absorbent underlayer aided by the squeezing of the ribs or other raised portions by the weight of the body which also serves to maintain the desired dryness of the nonabsorbent fibers. And the interstices of the upper layer also are of such size as to prevent the capillary retention therein of moisture, thereby further aiding the drying of the nonabsorbent layer after passage of the body fluids. The raised portions of the nonabsorbent upper layer provide an air buffer zone which enhances the ventilation of the nonabsorbent upper layer and the wearers skin, thereby maintaining the skin in a dry condition and removing the cause of most skin irritations and intlammations.

The combination of the nonabsorbent properties of the upper layer and the raised portions abovefthe plane of the upper layer result in virtual isolation of moisture from the wearers skin. The wearers skin is physically separated by the raised portions of the upper layer from the moisture contained in the absorbent layer. Instances of diaper rash, chapping, masceration 'of the skin, etc., are drastically reduced or entirely eliminated by diapers of the described construction. The diapers are comfortable to the wearer, simple to attach around the wearer, composed of high tensiley strength bers, and are resistant to soiling.

As another embodiment of the invention, the diaper may be constructed with hidden seams on three sides of the diaper. The upper layer may be placed with the raised portions 16 facing downward on top of the backing material 18, and the absorbent layer 13 placed beneath the backing material 18. The diaper may be sewed around three sides, then reversed inside out, so that the upper layer 10 now faces upward and the backing material 18 is on the bottom resulting in hidden stitching on three sides. The fourth side is then sewed to complete the bind- Further embodiments of the invention will occur immediately to those skilled in the art. It is therefore intended that the scope of the invention be described only by the appended claims and not by any specic embodiment described above.

I claim:

1. An improved diaper for preventing diaper rash and other skin irritations caused by skin contact with moisture, comprising an upper layer of nonabsorbent material constructed of nonabsorbent iibers, said upper layer containing interstices and having an uneven upper surface with raised portions in the form of sinuous knitted ribs thereon above the plane of the upper layer surface to allow the circulation of air around said raised portions and through said interstices; an underlayer having at least one sheet of absorbent material, both of said layers being substantially coextensive with each other in size and shape; and means for attaching said upper layer to said underlayer; said upper layer permitting the rapid passage of fluids from said upper surface of said nonabsorbent upper layer through said interstices to said absorbent underlayer, minimizing the capillary retention of said fluids in said interstices, and preventing the return flow of uids in said interstices, and preventing the return ow of fluids from said absorbent underlayer to said nonabsorbent upper layer; said raised portions of said nonabsorbent upper layer being in contact with the skin of the wearer when said diaper is being worn, and said raised portions of said upper surface permitting the flow of air around said raised portions and said skin of said diaper wearer to maintain said skin in a dry condition and to prevent skin irritations.

2. An improved diaper as described in claim 1 wherein a third layer is attached to the underside of said absorbent underlayer, said third layer being constructed of a material selected from the group consisting of absorbent and nonabsorbent materials, and said layer forming a backing for said diaper.

3. An improved diaper as described in claim y1, wherein said diaper has means vfor attaching said diaper around the wearer.

4. An improved diaper as described in claim 1, wherein said diaper has a portion of material extending beyond each of two opposite sides of said diaper for attaching said diaper around the wearer.

5. An improved diaper as described in claim 1, wherein said diaper is generally rectangular in shape having a depression generally centrally located on each of the 0pposite sides of said diaper with the general appearance of a body contour, said contoured diaper facilitating a more comfortable lit on the wearer.

6. An improved diaper as described in claim 1, wherein the nonabsorbent material is polypropylene.

7. An improved diaper for preventing diaper rash and other skin irritations caused by skin contact with moisture, comprising an upper layer of nonabsorbent material constructed of nonabsorbent bers, said upper layer containing interstices and having an uneven upper surface with raised portions thereon above the plane of the upper layer surface to allow the circulation of air around said raised portions and through said interstices; an intermediate layer of nonabsorbent material containing interstices, an underlayer having at least one sheet of absorbent material, all of said layers being substantially coextensive with each -other in size and shape; and means for connecting said layers together; said upper and said intermediate nonabsorbent layers permitting the rapid passage of fluids from said upper surface of said nonabsorbent upper layer through said interstices in said upper layer and said intermediate layer into said absorbent underlayer and minimizing the capillary retention of said iiuids in said interstices, and preventing the return iiow of uids from said absorbent under layer to said upper layer; said raised portions of said nonabsorbent upper layer being in contact with the skin of the wearer when said diaper is being worn, and said raised portions of said upper surface permitting the ow of air around said raised portions and said skin of said diaper wearer to maintain said skin in a dry condition and to prevent skin irritations.

8. An improved diaper as described in claim 7, wherein said nonabsorbent upper layer of said nonabsorbent intermediate layer are combined to form one single nonabsorbent layer.

9. An improved diaper as described in claim 7, wherein a fourth layer is attached to the underside of said absorbent underlayer, said fourth layer being constructed of a material selected from the group consisting of absorbent and nonabsorbent materials, and said layer forming a backing for said diaper.

10. An improved diaper as described in claim 7, wherein said said diaper has means for attaching said diaper around the wearer.

11. An improved diaper as described in claim 7, wherein said diaper has a portion of material extending beyond each of two opposite sides of said diaper, for attaching said diaper around the wearer.

12. An improved diaper as described in claim 7, wherein said diaper is generally rectangular in shape having a depression generally centrally located on each of the opposite sides of said diaper with the general appearance of a body contour, said contoured diaper facilitating a more comfortable fit on the wearer.

13. An improved diaper as described in claim 7, wherein the nonabsorbent material is polypropylene.

14. An improved diaper as described in claim 7, wherein said raised portions of said nonabsorbent upper layer are in the forrn of sinuous knitted ribs.

15. An improved diaper for preventing diaper rash and other skin irritations caused by skin contact with moisture, comprising an upper layer of knitted ribbed polypropylene fibers, said upper layer containing interstices and having an uneven upper surface with sinuous ribs extending from approximately 1 mm. to approximately 5 mm. above the plane of the upper layer surface, said ribs being approximately 1 mm. to approximately 5 mm. in cross-sectional dimension and being separated from each other by approximately 3 mm. to approximately l5 mm., said ribs permitting the circulation of air around said ribs and through said interstices; an underlayer having at least one sheet of absorbent material, both of said layers being substantially coextensive with each other in size and shape; and means for attaching said upper layer to said underlayer consisting of two fabric tabs extending from both of two opposite sides and being located near one end of said diapers; said upper layer permitting the rapid passage of fluids from said upper surface of said nonabsorbent upper layer through said interstices into said absorbent underlayer, minimizing the capillary retention of said fluids in said interstices, and preventing the return ow of uids from said absorbent underlayer to said nonabsorbent upper layer; said ribs of said nonabsorbent upper layer being in contact with the skin of the wearer when said diaper is being worn, and said ribs of said upper surface permitting the ow of air around said ribs and said skin of said diaper wearer to maintain said skin in a dry condition and to prevent skin irritations.

16. An improved diaper for preventing diaper rash and other skin irritations caused by skin Contact with moisture, comprising an upper layer of nonabsorbent material constructed of nonabsorbent bers, said upper layer containing interstices and having an uneven upper surface with ribs extending from approximately 1 mm. to approximately 5 mm. above the plane of the upper layer surface, said ribs being approximately 3 mm. to approximately 15 mm., said ribs permitting circulation of air around said ribs and through said interstices; an intermediate layer of nonabsorbent material containing interstices, an underlayer having at least one sheet of absorbent material, all three of said layers being substantially coextensive with each other in size and shape; and means for connecting said layers together consisting of two fabric tabs extending from both of two opposite sides and being located near one end of said diapers; said upper and said intermediate nonabsorbent layers permitting the rapid passage of uids from said upper surface of said nonabsorbent upper layer through said interstices in said upper layer and said intermediate layer into said absorbent underlayer, minimizing the capillary retention of said uids in said interstices, and preventing the return ow of fluids from said absorbent underlayer to said upper layer; said ribs of said nonabsorbent upper layer being in contact with the skin of the wearer when said diaper is being worn, and said ribs of said upper surface permitting the ow of air around said ribs and said skin of said diaper wearer to maintain said skin in a dry condition and to prevent skin irritations.

References Cited UNITED STATES PATENTS 2,545,674 3/1951 Ralph 128--287 2,566,844 9/1951 Laughead 128-284 2,695,025 11/1954 Andrews 128-284 2,905,176 9/1959 Davidson 128--284 3,113,570 12/1963 Holliday et al 128-284 3,216,421 11/1965 Devaud 128-287 3,237,625 3/1966 Johnson 12S-288 3,367,333 2/ 1968 Scheier 12S-284 CHARLES F. ROSENBAUM, Primary Examiner U.S. Cl. X.R. 66-200 

